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TABLE OF CONTENTS

LETTER OF TRANSMITTAL 02

ABOUT SAPPHIRE AND BLOW ROOM LINE 03

CARDINGDRAWING

04

COMBINGSIMPLEXRING FRAME

05

WINDINGPACKINGKNITTINGFIBER TESTING EQUIPMENTS

06

YARN TESTING EQUIPMENTSCONCLUSION

07

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Munawar ShahStudent of Textile Department Mehran University of Engineering,Jamshoro Sindh Pakistan

26th March, 2015

The ChairmanTextile departmentMehran University of Engineering,Jamshoro Sindh Pakistan

Respected sirAs requested, I am pleased to provide you this report covering the information regarding visit which was taken place on12th March, 2015 to the Sapphire Textile Mills Pvt Ltd.The objective of that visit was to give knowledge to the students of 14 batch about the industrial scenario especially Yarn Manufacturing (Spinning) and the operations performed in it. Furthermore that was for understanding of the functions of machines, technical knowledge used to manufacture yarn and the procedures for fault removing, comes in the manufacturing of it.

The outcome of that visit enabled the students to get knowledge about the circumstances at industrial work which shall help us in studies as well as in future.

Yours sincerely

Munawar Shah (Roll No: 14-13TE100)Student of Textile department, MUET

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TEXTILE INDUSTRYOF PAKISTAN

Textile is a term that comes from “texture” which is a Latin word that means “to weave”. A cloth is manufactured by weaving or knitting to form a fabric.The textile industry is often considered a backbone of the Islamic Republic of Pakistan’s economy. Pakistan’s textile Industry is the fourth Largest Cotton Producer, sixth largest importer of raw cotton.

INTRODUCTIONThe textile industry contributes approximately 8.5 percent of the country GDP. In Asia, Pakistan is the eighth largest exporter of textiles providing employment to 38 percent of the employer of the country.

OVERVIEWPakistan’s textile industry ranks amongst the top in the world. Cotton based textiles contribute over 60% to the total exports, accounts for 46% of the total manufacturing and provide employment to 38%manufacturing labor force. The availability of cheap labor and basic raw cotton as raw material for textile industry has played a major role in the growth of the Cotton Textile Industry in Pakistan.

ABOUT SAPPHIRESapphire mill is one of the largest manufacturer and exporter of yarn. They purchase raw material (Cotton) from the local source having high standard quality for the quality product and special fibers are imported. They market their product to the Asia, Europe, Australia and Korea. They believe that there is no shortcut for long term success.It was established in 1971 and at that time they had 12000 spindles, they worked hard, planned well and have come to the well known in the country as well as in the world in the spinning sector.

ABOUT VISITFirst we went to Sapphire by university point, after reaching there we wait for a while near garden and after that we were divided into two groups, one went with Sir Rafique and the other one went with Sir Nadir to the unit: 2. we had supervisor went for briefing about the spinning mill.First we went to the blow room, there is a mixing area there, where labors were opening the cotton bales and they were mixing them having different colors.

BLOW ROOM LINEBlow room consists of number of machines where fibers are opened, cleaned, mixed or blended and even feed to the card. 70% of the trash is removed from the fiber with providing low humidity for opening and cleaning them. For this purpose they use a blow room of Trutschler.

BALE OPENER BO It is a coarse cleaner having cleaning rollers which removes the heavy trash and create tufts.

METAL DETECTOR BY ARUGSIt detects the ferrous and the non-ferrous material from fibers.

PRE-CLEANER CL-PIt is pre cleaning machine having pair of roller and it cleans fiber gently (half beating point)

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INTEGRATED MIXER MX-I It has six chambers having chute feeding system integrated with CL-CI and CL-CIII. In its chambers there are optical sensor where they insert cards for continuous function and preventing it from machine stop. Every chamber has a pair of roller known as opening roller with cleaning roller where fiber cleans more and homogeneous mixer is formed in forms of sandwiches and then material goes into the next machine.

CL-CI It is a fine cleaning machine having two opening roller with one cleaning roller, fiber cleans here intensively because it has a full beating point.CL-CIII It is also fine cleaner having two opening roller with three cleaning roller, fiber cleans here more intensively because it has full beating point.

DUSTEX SP-DX It is the last machine in a blow room line which removes the dust by pneumatic system and stores the cotton and delivers material to the card

CARDINGCarding is the first process of yarn manufacturing and it is also known as heart of spinning and if it is efficient, the required product quality will be increased because it is said “Well carded is half spun”. In this process fibers are opened intensively, trash and dust is removed, fibers are aligned and sliver is formed. Sapphire has 30 cards.

CARD TC-03 AND TC-07 TRUTSCHLERThey both cards work on chute feeding system with four cans delivery and sliver tex was 6 ktex

SCUTCHER HOWA CMK-3

They had two scutcher, where lap was formed and that lap went to the card manually and then sliver was formed.

DRAWING

Drawing is the second most important process of yarn manufacturing where carded slivers are aligned, blended, dusts removing and doubling occurs with the help of rollers. In drawing department there was a temperature about 35 degree and more humidity for stretching the sliver and they had three kinds of draw frame which was actually used for more alignment, removing hooks, homogeneous blending and due to the manufacturing of Melange.

DRAW FRAME DYH-II AND DYH -500C TOYODA (BREAKER)

This draw frame has a primary action there; it has double delivery with special drafting system produce quality sliver at very high speed.

DRAW FRAME DX-8 TOYODA (INTERMEDIATE)

This draw frame aligns fiber more here having double delivery at very high speed.

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DRAW FRAME RSB-D-30 AND RSB-D-22 RIETER (FINISHER)

This was also for efficient performance with dual delivery and it has bulb after scanning roller which maintains moisture.

FANCY TOPS CAIPO

They had only one machine of it which was for colored sliver in which eight different colors slivers are put to get one colored sliver.

COMBING

Combing is an actually an additional process to make fine yarn where we align more fibers than the other process in which we remove short fibers and removes naps. It upgrades the yarn quality.

CM-10 TOYODA AND E7/6 RIETER

This is an actually comber machines in which they had six heads and there were two bulb at each machine over lap which maintains moisture. They produce sliver at high speed.

UNILAP FORMER E5/3

It is lap former machine for making combed yarn.

SIMPLEX

Simples is also one of the most important process where drawn sliver are further drafted, small amount of twist is imparted for strengthening and output which is roving having pencil like thickness is wound on the packages.

FL-16 TOYODA

They had more than 30 simplex which has 4/4 drafting system having 120 spindles. In its drafting zone inclined roller has apron made of rubber for further alignment and they had open flyer and closed flyer too with very high speed.

RING FRAME

Ring frame is the final machine of manufacturing yarn in which roving are drafted, impart twist and wound on the bobbins. The relative temperature was less there.

RY-IV TOYODA

They had more than forty ring frames in which they had 480 spindles and manual doffing.

FA-507-A CHINA

This machine had 516 spindles.

EJM-178

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It is compact ring frame of china.

WINDING

It is the process to make the packages of yarns is called winding.

MACHCONER 7V AND 7II

In this machine yarn is wound, naps are removed by untwisting and that waste of naps to the waste suction pipe goes out, hairiness is removed by providing wax.

PACKING

After winding of the yarn on bobbins it went for the conditioning room for 24 hours before packing, which increases strength of yarn, manage yarn to yarn friction and decreases wastages. There were 24 bobbins in one sack.

KNITTING MACHINE BY PAILUNG

It is a knitting machine where they produce a knitted fabric for checking their yarn quality and dimensions of different testings.

FIBER TESTING EQUIPMENTS

Textile fiber testing lab is a backbone of any industry where fibers properties are measured and its quality is assured, they classify too and they check even that those fibers carefully which directly affects the end product. In this testing is done by instruments which are handled by experienced persons according to the standards.

AFIS PRO BY USTER

This instrument checks the fiber maturity.

FIBROGRAPH BY SPINLAB

It checks the staple length of fiber..

MICRONAIRE

It checks the fiber fineness.

WASTE ANALYZER

It checks the trash in a fiber.

COLORIMETER

It checks the color of fiber.

STELOMETER

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It checks the tenacity of fiber.

YARN TESTING EQUIPMENTS

USTER TESTER

It checks the yarn evenness and quality.

SINGLE YARN TESTER

It checks the strength of single yarn.

COUNT ANALYZER

It finds the count of yarn.

FRICTION TESTER

It checks the durability of yarn.

YARN APPEARANCE BOARD MACHINE

It checks the irregularities in the yarn.

YARN WRAPPING MACHINE BY PAILUNG

I t wraps the yarns.

CONCLUSION

The industrial visit helped us to learn a lot which we had never learnt in our academics. The circumstances of an industry, office etiquettes and co-operative management gave us deep knowledge about an industrial work. During this visit we came to familiar with many machines, techniques, production and environment. We consider this opportunity to thank all the staff over there and the teachers who went with us, without them we couldn’t have completed this industrial visit and I hope it shall be arranged in future too.

THE END